Constant load toolpath planning and stiffness matching optimization in robotic surface milling

Freeform surfaces are widely present in the core components of advanced equipment such as aerospace and shipbuilding, and their high-level manufacturing is a key indicator of the national manufacturing industry. Industrial robots offer a promising solution for freeform surface milling due to their h...

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Bibliographic Details
Published in:International journal of advanced manufacturing technology 2024, Vol.130 (1-2), p.353-368
Main Authors: Liao, Zhao-Yang, Qin, Zhen-Zhong, Xie, Hai-Long, Wang, Qing-Hui, Zhou, Xue-Feng
Format: Article
Language:English
Subjects:
Algorithms
CAE) and Design
Computer-Aided Engineering (CAD
Conformal mapping
Cutting tool paths
Engineering
Industrial and Production Engineering
Industrial robots
Manufacturing
Matching
Material removal rate (machining)
Mechanical Engineering
Media Management
Milling (machining)
Optimization
Original Article
Robot dynamics
Robots
Stiffness
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Summary:Freeform surfaces are widely present in the core components of advanced equipment such as aerospace and shipbuilding, and their high-level manufacturing is a key indicator of the national manufacturing industry. Industrial robots offer a promising solution for freeform surface milling due to their high flexibility and large workspace advantages. However, maintaining stability in milling force and ensuring robot stiffness are crucial factors affecting the quality of surface machining. In this work, we propose a method for constant load toolpath planning and stiffness-based robot posture optimization in freeform surface milling. Firstly, we combine the conformal mapping algorithm and variable radius trochoidal trajectory to develop a toolpath planning method with constant cutting load, based on the material removal rate simulation according to the Dexel model. Moreover, we introduce an evaluation index for robot stiffness matching, considering the prediction of MRR. To optimize the sequence of posture changes under robot motion constraints, we employ the dynamic A* algorithm. This ensures that the robot maintains optimal stiffness performance throughout the machining process. Simulations and experimental studies validate the effectiveness and practicality of our proposed approach. These studies demonstrate that our method successfully maintains milling force stability and enhances robot stiffness, enabling more efficient freeform surface machining.
ISSN:0268-3768
1433-3015
DOI:10.1007/s00170-023-12639-9